Method and apparatus for evaluating the contents of a mailed envelope and if the envelope is safe to open

ABSTRACT

A method is provided for mailing a package to confirm to a recipient that the package is safe to open. The method includes the step of providing an envelope including a plurality of folded edges; including perforations formed along at least one of the folded edges; including a plurality of fold traps formed along the folded edge, each fold trap being adjacent at least one of the perforations; and, including a mouth. The method also includes the steps of placing contents in the envelope; closing the mouth of the envelope; addressing the envelope to the recipient; applying postage to the envelope; mailing the envelope to the recipient; and, inspecting, on receipt of the envelope by the recipient, the envelope to determine if at least one of the folded edges includes perforations and fold traps. The presence of the perforations and fold traps indicates that the envelope is safe to open.

[0001] This invention pertains to methods and apparatus for transporting, manufacturing, and processing envelopes.

[0002] More particularly, this invention pertains to a method and apparatus for determining if a mailed envelope contains particulate.

[0003] In a further respect, the invention relates to a system to enable the recipient of a mailed envelope to determine quickly if the envelope is safe to open.

[0004] In another respect, the invention relates to a system to facilitate inspection of the interior of a sealed envelope.

[0005] Conventional orthogonal envelopes have existed for many years. A variety of such envelopes are available, including letter envelopes and a variety of smaller and larger envelopes. In the great majority of cases, the contents of an envelope mailed to a recipient pose no physical danger to the recipient of the envelope. In some instances, however, individuals have mailed letter bombs to individuals, have put toxic substances in envelopes, have put disease containing powders in envelopes, or have included other potentially harmful contents in envelopes.

[0006] Accordingly, it would be highly desirable to provide an improved method and apparatus for determining whether the contents of an envelope are safe.

[0007] Therefore, it is a principal object of the instant invention to provide an improved method and apparatus for identifying the contents of an envelope.

[0008] Another object of the invention is to provide an improved method and apparatus for enabling the recipient of an envelope to readily identify an envelope which likely has contents that will not harm the recipient.

[0009] A further object of the invention is to provide an improved method for transmitting an envelope to a recipient which enables the recipient to determine if particulate is contained in the envelope.

[0010] Still another object of the invention is to provide an improved method for manufacturing a “substance safe” envelope that, due to the shape and dimension and function and visual appearance of the envelope, provides immediate reassurance to a recipient of the envelope that the envelope does not contain a harmful substance.

[0011] These and other, further and more specific objects and advantages of the invention will be apparent from the following detailed description of the invention, taken in conjunction with the drawings, in which:

[0012]FIG. 1 is a top view illustrating a sheet of material foldable to produce an envelope in accordance with the principles of the invention;

[0013]FIG. 2 is a perspective view illustrating the sheet of material of FIG. 1 folded into an envelope;

[0014]FIG. 3 is a side section view illustrating a fold trap and taken along section line 3-3 in FIG. 2; and,

[0015]FIG. 4 is a front view illustrating an alternate embodiment of an envelope employed in the invention.

[0016] Briefly, in accordance with my invention, I provide an improved method for determining if a container of particulate leaks during transport. The method includes the step of providing an envelope including a plurality of folded edges; including perforations formed along at least one of the folded edges; including a plurality of fold traps formed along one of the folded edges; and, including a mouth. The method also includes the steps of placing the container of particulate in the envelope; closing the mouth of the envelope; mailing the envelope; and, inspecting the perforations and fold traps for particulate to determine if particulate leaked from the container.

[0017] In another embodiment of the invention, I provide an improved method to facilitate determination of the contents of an envelope being transported to a recipient. The method includes the step of providing an envelope including a plurality of folded edges; including perforations formed along at least one of the folded edges; including a plurality of fold traps formed along the folded edge; and, including a mouth. The method also includes the steps of placing contents in the envelope; closing the mouth of the envelope; mailing the envelope; and, examining the interior of the envelope through at least one of the perforations to evaluate the contents of the envelope.

[0018] In a further embodiment of the invention, I provide an improved method of manufacturing an article. The method includes the steps of providing a flat piece of material foldable along selected fold lines to produce an envelope having a peripheral edge extending along the fold lines; and, making a plurality of openings through the flat piece of material along at least one of the fold lines such that when the piece of material is folded to form the envelope, the openings open along the peripheral edge of the envelope, and fold traps are formed each adjacent at least one of the openings. The method also includes the steps of folding the piece of material into a folded configuration forming an envelope with the openings and fold traps along at least one of the fold lines; and, securing together portions of the folded piece of material to maintain the folded piece of material in the folded configuration.

[0019] In still another embodiment of the invention, I provide an improved method for mailing a package to enable a recipient to evaluate the contents of the package to determine if the contents include loose powder. The method includes the step of providing an envelope including a plurality of folded edges; including perforations formed along at least one of the folded edges; including a plurality of fold traps formed along the folded edge, each fold trap being adjacent at least one of the perforations; and, including a mouth. The method also includes the steps of placing contents in the envelope; closing the mouth of the envelope; addressing the envelope to the recipient; mailing the envelope to the recipient; and, inspecting, on receipt of the envelope by the recipient, the perforations and fold traps for the presence of loose powder in the envelope.

[0020] In still a further embodiment of the invention, I provide a method for mailing a package to confirm to a recipient that the package is safe to open. The method includes the step of providing an envelope including a plurality of folded edges; including perforations formed along at least one of the folded edges; including a plurality of fold traps formed along the folded edge, each fold trap being adjacent at least one of the perforations; and, including a mouth. The method also includes the steps of placing contents in the envelope; closing the mouth of the envelope; addressing the envelope to the recipient; applying postage to the envelope; mailing the envelope to the recipient; and, inspecting, on receipt of the envelope by the recipient, the envelope to determine if at least one of the folded edges includes perforations and fold traps. The presence of the perforations and fold traps indicates that the envelope is safe to open.

[0021] In yet a further embodiment of the invention, I provide an improved method of manufacturing an article. The method includes the steps of providing a flat piece of material; making a plurality of perforations through the flat piece of material along at least one perforation line which will be folded to produce an envelope and which will, when folded, produce fold traps each adjacent at least one of the openings; cutting from the piece of material a smaller piece of material foldable along lines including the perforation line to produce an envelope; folding the piece of material into a folded configuration forming an envelope including a peripheral edge folded along the perforation line and including fold traps along the perforation line; and, securing together portions of the folded piece of material to maintain the folded piece of material in the folded configuration.

[0022] In yet another embodiment of the invention, I provide an article of w manufacture comprising an envelope including a front; a back; a plurality of folded edges; perforations formed along at least one of the folded edges; a plurality of fold traps formed along the folded edge, each fold trap being adjacent at least one of the perforations; and, a mouth.

[0023] Turning now to the drawings, which depict the presently preferred embodiments of the invention for the purpose of illustrating the practice thereof and not by way of limitation of the scope of the invention, and in which like reference characters refer to corresponding elements throughout the several views, FIG. 1 illustrates a flat piece 10 foldable along lines 15 to 18 to produce a conventional orthogonal envelope. While envelopes of any shape and size and having any selected number of peripheral edges can be utilized in the practice of the invention, it is expected that the large majority of envelopes utilized in the invention will be orthogonal and include four folded edges, each of which is parallel or normal to the other edges. As used herein, a circular (or elliptical) envelope is assumed to have two peripheral edges, one for each semi-circular side of the envelope. Piece 10 typically, although not necessarily, comprises a relatively thin sheet of paper or other material. Material 10 includes a rectangular central area 30 having a front 31 and a back 32 (FIG. 2). Generally triangular members 21, 22, 23, 24 are attached to or integrally formed with area 30. Member 21 includes peripheral edge 11. Member 21 functions as the flap used to close the mouth 60 of the envelope. Member 22 includes peripheral edge 14. Member 23 includes peripheral edge 13. Member 24 includes peripheral edge 12.

[0024] When piece 10 is folded, member 21 is folded inwardly toward area 30 along dashed line 15 to produce fold line 15A; member 22 is folded inwardly toward area 30 along dashed line 16 to produce fold line 16A; member 23 is folded inwardly toward area 30 along dashed line 17 to produce fold line 17A; and, member 24 is folded inwardly toward area 30 along dashed line 18 to produce fold line 18A (FIG. 2).

[0025] Openings or perforations are formed through piece 10 along dashed lines 17 and 16. Semi-circular openings 26 each include an edge extending along line 17. Circular openings 26 extend through and to either side of line 17. Circular openings 34 extend through and to either side of line 16. Circular openings 27 are offset slightly from line 17 but are considered to be formed along line 17. Openings with a portion that is within about one-eighth of an inch of line 17 (or line 15, 16, 18) are considered to be formed along line 17. It is, however, preferred that openings formed along line 17 include a portion that at least in part lies on or extends through line 17, as do openings 25, 26. When at least a portion of an opening 25, 26 lies on or passes through line 17, inspection of the inside of the resulting envelope with a sensor 47, 48 is, as will be described, facilitated. Openings 25-27, 34 are formed along one or more folded edges of the envelope that results when piece 10 is folded. The shape and dimension of openings 25-27, 34 formed along a folded edge can vary as desired.

[0026]FIG. 2 illustrates the envelope 100 produced when piece 10 is folded. Members 22 and 24 are folded first, followed by member 23. Peripheral edge 13 overlies and covers a portion of the peripheral edge 14 of member 22 and of the peripheral edge 12 of member 24. In order to maintain the folded configuration of FIG. 2, the peripheral edge 13 of member 23 is glued or otherwise affixed in conventional fashion to the portions of edges 14 and 12 that are overlaid by edge 13.

[0027] The inside of envelope 100 can be inspected by using a sensor 48 positioned at a desired location near or spaced away from envelope 100; by positioning a sensor 48 near an opening 25-27, 34; by directly contacting at least a portion of an opening 25 to 27, 34 with a sensor 48; by a person's using his or her eye 47 as a sensor to look at an opening 25 to 27, 34; by a person using his eye 47 to look through an opening 25 to 27, 34 into the interior of an envelope; by positioning a sensor 48 adjacent or in contact with a fold trap 45, 46, 43, 41; or, by a person's using his or her eye to examine the fold trap, including looking at the edge of an opening adjacent the fold trap to see if there is powder or some other substance captured in the fold trap.

[0028] The fold traps 45, 46, 43, 41 are important in the practice of the invention because they often function to capture a portion of powder, particulate, or some other substance which can otherwise escape through openings 25 to 27, 34. Consequently, fold traps 45, 46, 43, 41 and openings 25 to 27, 34 collectively perform the dual function of allowing powders or other unwanted substances to escape from envelope 100 while capturing a least a small sample in the fold traps to enable an individual to determine that a source of powder or some other substance was, or is still is, in envelope 100.

[0029]FIG. 3 illustrates a fold trap 40. Trap 40 includes a portion of fold line 17A, a portion of member 30, and a portion of member 23 opposing and typically generally parallel to member 30. Trap 40 tends to capture in space 70 powder, particulate or other substances in envelope 100.

[0030]FIG. 4 illustrates an envelope 50 having the same shape and dimension as envelope 100, except that different sized semi-circular openings 53, 54 are formed in envelope 50 instead of openings 25-27, 34. The front 30A of envelope 50 is addressed 51 and provided with postage 52. As used herein, an envelope is mailed if it is deposited with the United States Postal Service, with Federal Express, with UPS, or with some other service that will deliver the envelope to a designated recipient. The person the envelope is addressed to is a recipient. Personnel in the United States Postal Service, Fed Ex, UPS, etc. who handle the envelope 50 during its delivery to the addressee are also considered recipients because they can inspect, handle, and view the envelope 50. As used herein, postage is applied to an envelope when postage stamps or postage meter labels are attached to an envelope. Postage is also considered applied when paperwork necessary to deliver an envelope is attached to or accompanies the envelope. This is the case with Fed Ex or UPS or other delivery services where actual postage is not applied but the customer is billed for the service.

[0031] In FIG. 1, openings or perforations 25 to 27, 34 can be formed through piece 10 before it is cut out of a larger pieces of material 20.

[0032] In use, perforations 25 to 27, 34 are formed through a piece 10. Piece 10 is shaped and dimensioned to be folded along selected lines 15 to 18 to produce an envelope. Perforations 26, 34 can also be formed by punching piece 10 after it is folded into an envelope. Consequently, as used herein, the steps of forming openings and folding piece 10 are considered equivalent to the reverse, i.e., are considered equivalent to folding piece 10 and then forming openings in the resulting envelope configuration. Piece 10 is folded into an envelope. Member 23 is glued to members 22 and 24 to maintain the folded envelope configuration shown in FIG. 2.

[0033] One method practiced in accordance with the invention allows evaluation of whether powder is leaking from a container in an envelope 100 at any point along the path of travel taken by an envelope after it has been mailed. This is accomplished by inspecting openings 25 to 27, 34 and/or fold traps 45, 46, 43, 41 for signs of powder.

[0034] Another method practiced in accordance with the invention permits the interior of an envelope 100 to be inspected. A sensor 48 is positioned adjacent an opening 26, in the opening, through the opening into the envelope, or at some position (possibly spaced away from the envelope 100) which permits material extending into or through the opening or a fold trap to be detected and evaluated, and/or which permits the contents of envelope 100 to otherwise be evaluated.

[0035] A further method advantageously practiced in the invention is addressing and mailing an envelope 100 to a recipient so that the recipient on receiving the envelope can inspect openings and fold traps to see if loose powder is present.

[0036] A particular advantage of another method of the invention is that when a recipient receives an envelope 100, the recipient visually inspects the envelope and notes that openings and fold traps are present. This indicates to the recipient that it is unlikely that there is a powder or other particulate present in the envelope because a person sending the envelope would ordinarily not send particulate or small objects in an envelope provided with peripheral openings 25 to 27, 34. Consequently, the mere presence of openings and fold traps indicates there is less risk handling envelope 100 because there is less risk there is a dangerous particulate or other substance in the envelope. The openings and fold traps give the envelope a shape and dimension that is readily recognized by a user and that indicates the functions of the envelope in allowing ready inspection of the interior of the envelope, in allowing particulate to escape, and in trapping substances in fold traps along peripheral edges of the envelope.

[0037] In FIG. 4, orthogonal envelope 50 includes peripheral edges 71, 72, 73, 74. The length of the periphery of envelope 50 is obtained by summing the lengths of each of these four edges. In the practice of the invention, it is preferred that 10% to 95%, preferably 20% to 90%, most preferably 25% to 80% of the length of each edge in which openings 53, 54 are formed be occupied by the openings. For example, when the diameters of each of the semicircular openings 53, 54 along edge 71 are summed, the total of the diameters of the openings is about 40% of the length of edge 71. The length of edge 71 is indicated by arrows A in FIG. 4. While openings 53, 54 can be formed along one or more peripheral edges 71, 72, 73, 74, it is preferred that openings be formed along each peripheral edge of an envelope. 

Having described my invention in such terms as to enable those of skill in the art to make and practice it, and having described the presently preferred embodiments and best mode thereof, I claim:
 1. A method for determining if a container of particulate leaks during transport, including the steps of (a) providing an envelope including (i) a plurality of folded edges, (ii) perforations formed along at least one of said folded edges, (iii) a plurality of fold traps formed along said one of said folded edges, and, (iv) a mouth; (b) placing the container of particulate in said envelope; (c) closing said mouth of said envelope; (d) mailing said envelope; (e) inspecting said perforations and fold traps for particulate to determine if particulate leaked from said container.
 2. A method to facilitate determination of the contents of an envelope being transported to a recipient, including the steps of (a) providing an envelope including (i) a plurality of folded edges, (ii) perforations formed along at least one of said folded edges, (iii) a plurality of fold traps formed along said one of said folded edges, and, (iv) a mouth; (b) placing contents in said envelope; (c) closing said mouth; (d) mailing said envelope; and, (e) examining the interior of said envelope through at least one of said perforations to evaluate the contents of said envelope.
 3. A method of manufacturing an article, including the steps of (a) providing a flat piece of material foldable along selected fold lines to produce an envelope having a peripheral edge extending along said fold lines; (b) making a plurality of openings through said flat piece of material along at least one of said fold lines such that when said piece of material is folded to form the envelope (i) said openings open along the peripheral edge of the envelope, and (ii) fold traps are formed each adjacent at least one of said openings; (c) folding said piece of material into a folded configuration forming an envelope with said openings and fold traps along at least one of said fold lines; and, (d) securing together portions of said folded piece of material to maintain said folded piece of material in said folded configuration.
 4. A method for mailing a package to enable a recipient to evaluate the contents of the package to determine if the contents include loose powder, including the steps of (a) providing an envelope including (i) a plurality of folded edges, (ii) perforations formed along at least one of said folded edges, (iii) a plurality of fold traps formed along said one of said folded edges, each fold trap being adjacent at least one of said perforations, and (iv) a mouth; (b) placing contents in said envelope; (c) closing the mouth of said envelope; (d) addressing said envelope to the recipient; (e) mailing said envelope to the recipient; and, (f) inspecting, on receipt of said envelope by the recipient, said perforations and fold traps for the presence of loose powder in the envelope.
 5. A method for mailing a package to confirm to a recipient that the package is safe to open, including the steps of (a) providing an envelope including (i) a plurality of folded edges, (ii) perforations formed along at least one of said folded edges, (iii) a plurality of fold traps formed along said one of said folded edges, each fold trap being adjacent at least one of said perforations, and (iv) a mouth; (b) placing contents in said envelope; (c) closing said mouth of said envelope; (d) addressing said envelope to the recipient; (e) applying postage to said envelope; (f) mailing the envelope to the recipient; and, (g) inspecting, on receipt of said envelope by the recipient, said envelope to determine if at least one of said folded edges includes perforations and fold traps, the presence of said perforations and fold traps indicating that said envelope is safe to open.
 6. A method of manufacturing an article, including the steps of (a) providing a flat piece of material; (b) making a plurality of perforations through said flat piece of material along at least one perforation line which will be folded to produce an envelope and which will, when folded, produce fold traps each adjacent at least one of said openings; (c) cutting from said piece of material a smaller piece of material foldable along lines including said perforation line to produce an envelope; (d) folding said piece of material into a configuration forming an envelope including a peripheral edge folded along said perforation line and including fold traps along said perforation line; and, (e) securing together portions of said folded piece of material to maintain said folded piece of material in said configuration.
 7. An article of manufacture comprising an envelope including (a) a front; (b) a back; (c) a plurality of folded edges, (d) perforations formed along at least one of said folded edges, (e) a plurality of fold traps formed along said one of said folded edges, each fold trap being adjacent at least one of said perforations, and (f) a mouth. 